Functional Binder Jetting for Additive Manufacturing
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Solution Overview
Problem
Traditional binder jetting methods face challenges with porosity, shrinkage, and contamination due to the de-binding process, which compromise the mechanical properties of 3D printed products and make them difficult to recycle.
Innovation Solution
The use of functional binder jetting, where a functional binder infiltrates into the powder bed, fuses particles in situ, and becomes part of the build material, eliminating the need for post-processing steps like de-binding and infiltration, allowing for the embedding of structures like sensors and actuators directly during the printing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional binder jetting methods are used with sacrificial binder, then the structure can be self-supporting during building, but porosity and mechanical properties deteriorate due to de-binding process
Solution Approach 1:
The binder material composition is changed from sacrificial organic binder to functional ceramic binder (alumina, silica, zirconia). This parameter change transforms the binder from being removed to remaining as part of the final structure, eliminating porosity issues while maintaining green strength during printing.
Solution Approach 2:
The patent uses composite material system where ceramic binder particles are combined with metal or ceramic powder particles. The functional binder acts as both binding agent and structural material, creating a composite where the binder becomes part of the final component rather than a temporary support.
2Reliability
If de-binding and infiltration post-processing steps are added, then porosity is reduced, but manufacturing complexity and time increase
Solution Approach 1:
The patent extracts and eliminates the de-binding and infiltration post-processing steps from the manufacturing process. By using functional binder that remains in the final structure, these complex post-processing operations become unnecessary, simplifying the overall manufacturing workflow.
Solution Approach 2:
The functional binder performs the dual function of binding particles during printing and forming the final structural material, eliminating the need for subsequent infiltration steps. This preliminary action of using appropriate binder material prevents the need for later corrective post-processing.
3Strength
If functional binder is used to fuse particles in situ, then porosity is reduced and mechanical properties improve, but the binder must infiltrate powder bed effectively
Solution Approach 1:
The binder formulation parameters are optimized including particle size distribution, viscosity, and composition ratios of ceramic binders (alumina, silica, zirconia). These parameter changes ensure effective infiltration into the powder bed while achieving proper fusion and mechanical properties.
Solution Approach 2:
The patent utilizes the porous structure of the powder bed during printing to facilitate binder infiltration. The functional binder is applied in a manner that allows it to penetrate the porous powder structure effectively, ensuring complete coverage and fusion of particles.
4Object-generated harmful factors
If sacrificial binder is removed through de-binding, then contamination is reduced, but shrinkage and mechanical property loss occur
Solution Approach 1:
The binder material parameter is changed from organic sacrificial binder to inorganic functional ceramic binder. This parameter change eliminates contamination from organic decomposition while preventing shrinkage through controlled sintering of the ceramic binder particles that remain in the final structure.
Solution Approach 2:
The patent converts the previously harmful presence of binder (requiring removal) into a beneficial structural component. The functional binder that would have been considered contamination or waste is instead utilized as part of the final material structure, improving both cleanliness and mechanical properties.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in 3D printed parts with improved mechanical properties, reduced porosity, and enhanced functionality, enabling the production of complex, functional components suitable for industries like aerospace and automotive without the need for additional post-processing steps.
Implementation Method 1
a functional binder jetting process in which a functional binder is jetted from one or more inkjet print heads onto a powder bed and infiltrates into pores in the powder bed and locally fuses particles in the powder bed in situ
Implementation Method 2
a functional binder jetting process in which a functional binder is jetted from one or more inkjet print heads onto a powder bed
Data Source
AI summary
A method of 3D printing in which a 3D product is built up layer by layer by jetting from print heads includes forming part of a 3D product by a functional binder jetting process; jetting one or more material in a 2D pattern to form a structure on said part; completing the formation of the 3D product by continuing the functional binder jetting process, so that said structure becomes embedded in said product. Functional binder jetting may include: providing a layer of a powder bed; jetting a functional binder onto selected parts of said layer, wherein said functional binder infiltrates into pores in the powder bed and locally fuses particles of the powder bed in situ; sequentially repeating applying a layer of powder on top and selectively jetting functional binder, multiple times, to provide a powder bed bonded at selected locations by printed functional binder.